Instruction Manual Model 1022 / 1025 Control Concepts Power
Contents
1. 1022 8 1025 3 05 10 2007 INSTALLATION DRAWINGS Continued 24 Vac Secondarv 120 or 240 Volt Primarv ar 2 375 sl a Figure 4 120 240 Volt Primary Transformer 2 99 Figure 5 480 Volt across H1 and H4 of Primary Jumper across X2 amp X3 to create 24 Vac on Secondary MODEL 1022 amp 1025 4 05 10 2007 MODEL 1022 CONNECTIONS CONTROL SIGNAL CONNECTIONS TO SUPPLY Oi QD ch ima Zk TRANSFORMER NO PHASING REQUIRED e Q O sa BE se a gt x man ia 4 CCW CW 0 10 Vdc 0 5 Vdc POT MODEL 1025 CONNECTIONS TO SUPPLY TRANSFORMER NO PHASING REQUIRED Q AS HI 1 l4 4 20 mA MODEL 1022 8 1025 5 05 10 2007 ZERO AND SPAN ADJUSTMENTS The zero and span adjustments have been factorv adjusted to provide zero load voltage when the minimum command signal is applied and to provide rated output voltage to the load when the maximum command signal is applied Further adjustment of these settings should not be required If it is desired to readjust the zero and span settings the following procedures should be followed Voltage and or current measurements should be taken with meters that provide true RMS readings due to the chopped waveforms provided bv the SCR controller Adjust the zero potentiometer with the minimum command signal applied such that the load voltage is just zero Clockwise rotation of both the span and zero potentiometer i2. accepts a 4 20mA command signal Both controllers control the RMS voltage to the load proportional to the command signal independent of line voltage hanges The controllers include soft start and missing cvcle detection which on power interruptions of one half cvcle or more sets the load voltage to zero and then increases the load voltage to the desired voltage at a predetermined rate his eliminates inrush currents that can occur due to loads with a low cold resistance or because of saturation when a transformer is used between the controller and the load The command signal is electricallv isolated from line and load voltages and all are electricallv isolated from the heat sink SPECIFICATIONS CONTROL MODE Single phase Phase angle RMS value of the voltage applied to the load COMMAND SIGNAL SIGNAL INPUT IMPEDANCE Model 1022 0 5 Vdc 100K 0 10 Vdc 200K Potentiometer 200K 1K pot recommended 20K permissible Model 1025 4 20 mA 200 Ohms CONTROL RANGE 6 to 97 of line voltage typical LINEARITY RMS load voltage is linear within 2 of span of the command signal ZERO AND SPAN User adjustable over range of 20 of span ADJUSTMENTS ISOLATION Dielectric strength input line amp load voltage heatsink 4000V RMS Insulation resistance input line amp load voltage heatsink Lu ohms Maximum capacitance input to output 8pf MOUNTING Must be mounted on vertical surface with fins vertical Unit may be mounted adjacent to each othe
3. limit the maximum load voltage to about 97 of the supply voltage UPOr Figure 6 Phase angle control at 50 power MODEL 1022 8 1025 8 05 10 2007
4. 08 19 20 70 150 19 39 33 60 INSTALLATION The controller must be mounted on a vertical surface such that the heat radiating fins are vertical and located in an environment that will not exceed 55 C and that is protected from dirt and dust The wiring must be per local electrical codes The supply and load terminals will accept up to 6 wire The terminals for the circuit transformer and control signals accept wire up to 14 The terminals for the control signals and circuit transformer are plug in and may be removed by pulling perpendicular to the circuit card CAUTION 1 The circuit transformer must be connected to the same supply as the controller and the load A common installation error has been that of the circuit transformer being powered from a different phase or being connected across the SCR module rather than from the supply 2 Do not over tighten the wire connections NOTE It is recommended that the controller and the load be protected with fast acting class T fuses such as described in the specification portion or this instruction manual RECOMMENDED TIGHTENING TORQUE OG USD CONNECTORS Wine Size we 35 IN LBS 40 IN LBS 45 IN LBS 50 IN LBS RECOMMENDED TIGHTENING TORQUE Toncue 50 mess MODEL 1022 amp 1025 2 05 10 2007 INSTALLATION DRAWINGS Figure 2 MO1 Mounting Option 7 50 Figure 3 70 Amp MODEL
5. 2 12 70 42110 0460 390 FK 62T90 1022 48 10 or 1025 48 10 1652 48 10 42110 0460 315 FK 62T15 1022 48 20 or 1025 48 20 1652 48 20 42110 0460 325 FK 62T25 1022 48 30 or 1025 48 30 1652 48 30 42110 0460 335 FK 62T35 1022 48 40 or 1025 48 40 1652 48 40 42110 0460 350 FK 62T50 1022 48 70 or 1025 48 70 1652 48 70 42110 0460 390 FK 62T90 The assembly includes the SCR relay a thermal conductive pad an MOV and an instruction sheet The fuse kit includes two fuses of appropriate rating for the frame size and a fuseblock Control concepts recommends that fuses be rated at 120 to 125 of maximum load current REFERENCE DRAWINGS Model 1022 Schematic B1000466 Model 1025 Schematic B1000324 Transformer Inst Dwg AS1401 MODEL 1022 8 1025 6 05 10 2007 TROUBLE SHOOTING CAUTION High voltage exists on the supplv and load terminals of this controller and mav exist on other equipment located near the controller Use extreme caution to avoid electrical shock The LED located on the controller circuit can be used to aid in determining problems This LED varies in intensitv proportional to the command signal and therefore should be proportional to the load voltage THE FOLLOWING ARE SVMPTOMS AND POSSIBLE CAUSES SYMPTOMS POSSIBLE CAUSES NO LOAD POWER LED not ON Determine that the command sigal is applied to the controller Determine that 24 volts is applied to the circuit NO LOAD POWER LED intensity can be varied Determine that all fuse
6. Control Concepts Model 1022 1025 Power Control Svstem Instruction Manual Ma Series 2 Controlli i SCR Power Controllers Another quality product from RX RESEARCH INC DRVING A CURING A HEATING 7128 Shadv Oak Road Eden Prairie MN 55344 USA 952 949 9009 Fax 952 949 9559 www researchinc com CONTROL CONCEPTS INC 2 VEAR LIMITED WARRANTV CONTROL CONCEPTS INC warrants that the products delivered will be as described in the sales order or contract CONTROL CONCEPTS INC warrants to the original user that CONTROL CONCEPTS INC products will be free from defects in materials and workmanship for a period of two 2 years after the date CONTROL CONCEPTS INC ships such products If any CONTROL CONCEPTS INC product is found to be defective in material or workmanship during the applicable warranty period CONTROL CONCEPTS INC s entire liability and purchasers sole and exclusive remedy shall be the repair or replacement of the defective product at CONTROL CONCEPTS INC s election CONTROL CONCEPTS INC shall not be liable for any costs or expenses whether direct or indirect associated with the installation removal or re installation of any defective product All shipping and freight costs are the responsibility of the customer CONTROL CONCEPTS INC s limited warranty shall not be effective or actionable unless there is compliance with all installation and operating instructions furnished by CONTROL C
7. ONCEPTS INC or if the products have been modified or altered without the written consent of CONTROL CONCEPTS INC or if such products have been subject to accident misuse mishandling tampering negligence or improper maintenance Any warranty claim must be submitted to CONTROL CONCEPTS INC in writing within the stated warranty period CONTROL CONCEPTS INC s limited warranty is made in lieu of and CONTROL CONCEPTS INC disclaims all other warranties whetherexpressed orimplied including but not limited to any IMPLIED WARRANTY OF MERCHANTABILITY ANY IMPLIED WARRANTY OF FITNESS FORA PARTICULAR PURPOSE any implied warranty arising out of a course of dealing or of performance custom or usage of trade CONTROL CONCEPTS INC SHALL NOT UNDERANY CIRCUMSTANCES BE LIABLE FORANY DIRECT INDIRECT INCIDENTAL SPECIAL OR CONSEQUENTIAL DAMAGES INCLUDING BUT NOT LIMITED TO LOSS OF PROFITS REVENUE OR BUSINESS OR DAMAGE OR INJURY TO PERSONS OR PROPERTY IN ANY WAY RELATED TO THE MANUFACTURE OR THE USE OF ITS PRODUCTS The exclusion applies regardless of whether such damages are sought based on breach of warranty breach of contract negligence strict in tort or any other legal theory even if CONTROL CONCEPTS INC has notice of the possibility of such damages By purchasing CONTROL CONCEPTS INC s products the purchaser agrees to the terms and conditions of this limited warranty WARNING The Control Concepts Inc power controllers us
8. e power thyristors to switch voltage to the connected load Line voltage must be assumed at the output terminals at all times even when the control signal has been removed and the load voltage appears to be off It has been mandated by the National Electrical Code and the Occupational Safety and Heath Act of 1970 that a physical disconnect be opened ahead of all remotely actuated controls before performing any maintenance work on the controller or its connected load PROPRIETARY DATA Copyright 2007 Control Concepts Inc Chanhassen MN 55317 The information and design disclosed herein are the property of Control Concepts Inc and may not be used reproduced or disclosed in any form except as granted in writing by CONTROL CONCEPTS INC 7870 PARK DRIVE CHANHASSEN MN 55317 PHONE 952 474 6200 TOLL FREE 800 765 2799 FAX 952 474 6070 www ccipower com MODEL 1022 8 1025 TABLE OF CONTENTS DESCRIPTION 1 SPECIFICATIONS 1 INSTALLATION 2 INSTALLATION DRAWINGS 3 MODEL 1022 CONNECTIONS 5 MODEL 1025 CONNECTIONS 5 ZERO AND SPAN ADJUSTMENTS 6 RECOMMENDED SPARE PARTS AND FUSES 6 REFERENCE DRAWINGS 6 TROUBLE SHOOTING 7 MANUFACTURED BY 7 MODEL NUMBER IDENTIFICATION 8 THEORY OF OPERATION 8 MODEL 1022 8 1025 i 05 10 2007 DESCRIPTION The models 1022 and 1025 are single phase phase angle SCR power controllers The controllers are the same except the 1022 accepts command signals of 0 5Vdc 0 10Vdc or a potentiometer signal The model 1025
9. load and line connection at the controller MANUFACTURED BY CONTROL CONCEPTS 7870 PARK DRIVE CHANHASSEN MN 55317 TEL 952 474 6200 FAX 952 474 6070 TOLL FREE 800 765 2799 www ccipower com U S A MODEL 1022 8 1025 7 05 10 2007 MODEL NUMBER IDENTIFICATION 102X VV AA SCXXX MOXX X 2 for 1022 5 for 1025 1022 0 5Vdc 0 10Vdc or POT control 1025 4 20mA input VV Rated voltage 12 120Vac 24 240Vac 48 480Vac 57 570Vac AA Rated amps 10 20 30 40 or 70 amps Note The addition of SCXXX implies that the controller has been modified to have a different input command For example a SC1 5Vdc implies the controller has been modified to operate with a 1 5Vdc control signal The addition of MOXX implies a special mounting or assembly of the controller THEORY OF OPERATION The model 1022 and 1025 are phase angle controllers therefore the load voltage is controlled by turning the appropriate SCR on for a portion of each electrical half cycle as shown in Figure 6 The waveform shown as E represents the ON time of the SCRs in each half cycle and therefore represents the voltage waveform applied to the load As the load voltage is increased the SCRs are turned ON earlier in the cycle As the load voltage is decreased the SCRs are turned on later in cycle The load voltage can be varied with infinite resolution from 0 to 100 percent of the line voltage Circuit tolerances may
10. ncrease the load voltage Adjust the span potentiometer with the maximum command signal applied such that load voltage equals the rated voltage of the controller It may be necessary to repeat these steps due to interaction that can occur NOTE The 1022 and 1025 controllers have line voltage compensation therefore if the supply voltage is above the nominal rating the controller will supply the nominal rated voltage to the load For example if a controller rated for 240 volt operation is supplied from a 260 volt supply and the maximum command signal is applied the controller will supply only 240 volts to the load thereby eliminating the effects of line voltage changes RECOMMENDED SPARE PARTS AND FUSES RECOMMENDED RECOMMENDED FUSES typical REPLACEMENT SCR Alternative fuse size is 125 of maximum load current MODEL ASSEMBLY CCI PART No BUSSMAN CCI PART No PART No FUSEKIT 1022 12 10 or 1025 12 10 1652 12 10 42110 0460 315 FK 62T15 1022 12 20 or 1025 12 20 1652 12 20 42110 0460 325 FK 62T25 1022 12 30 or 1025 12 30 1652 12 30 42110 0460 335 FK 62T35 1022 12 40 or 1025 12 40 1652 12 40 42110 0460 350 FK 62T50 1022 12 70 or 1025 12 70 1652 12 70 42110 0460 390 FK 62T90 1022 24 10 or 1025 24 10 1652 12 10 42110 0460 315 FK 62T15 1022 24 20 or 1025 24 20 1652 12 20 42110 0460 325 FK 62T25 1022 24 30 or 1025 24 30 1652 12 30 42110 0460 335 FK 62T35 1022 24 40 or 1025 24 40 1652 12 40 42110 0460 350 FK 62T50 1022 24 70 or 1025 24 70 165
11. r Heatsink is electrically isolated LINE VOLTAGE 120 240 480 or 575 Vac 10 20 50 60 Hertz DIAGNOSTIC INDICATOR The intensity of an LED varies as a function of the command signal Feature provides a quick and safe means to check controller operation PHYSICAL Weight 10 40 Amp 2 Ibs 70 Amps 6 Ibs Dimensions Refer to installation drawings ENVIRONMENT Operating 0 to 55 C 32 to 131 F Storage 40 to 80 C 40 to 176 F Humidity 0 to 95 Non condensing DV Dt AND TRANSIENT 200 volts usec minimum VOLTAGE PROTECTION A dv dt snubber and a metal oxide varistor MOV are provided to protect against high frequency transients dv dt and voltage spikes DISSIPATION 1 5 watt per amp of controlled current RECOMMENDED FUSING Special semiconductor fuses are not required It is advised that the controller and load be protected with fast acting class T fuses such as Bussmann type JJN 300V or JJS 600V fuses Control Concepts maintains an inventory of fuses and fuse holders for your convenience It is recommended that a fuse rated 120 to 125 of maximum load current be selected MODEL 1022 amp 1025 1 05 10 2007 SPECIFICATIONS Continued SURGE CURRENT RATING KW ac Continuous RMS 1 Peak 1 Cycle 1 2 trating 120 Vac 240 Vac 277 RMS rating Second Non Repetive 81 i 480 Vac 575 Vac 10 22 1 20 2 40 2 77 4 80 5 75 20 40 2 40 4 80 5 54 9 60 30 80 3 60 7 20 8 31 14 40 40 150 4 80 9 60 11
12. s are OK If the voltage across the SCR module is equal to the line voltage the SCR module has probably failed NOTE If a replacement SCR module is ordered specify the voltage and current rating of the controller and the serial number of the failed unit LOAD POWER IS MAXIMUM AND CANNOT BE Determine that the command signal can be adjusted to REDUCED LED is ON zero Also remove the green plug in connector to remove the command signal If the LED is not off the circuit card has failed LOAD POWER IS MAXIMUM AND CANNOT BE Remove the 24Vac plug in connector If the load still has REDUCED LED is OFF power the SCR module has probably failed as a short allowing full power at be applied to the load To determine if the SCR module has shorted remove power and then the line and load connections and measure the resistance across the line and load terminals on the SCR module If the resistance is less than 10000 ohms the modual has failed NOTE If a replacement SCR module is ordered specify the voltage and current rating of the controller and the serial number of the failed unit LOAD VOLTAGE SNAPS ON Determine that the primary of the circuit transformer is connected to the same supply as the controller and load MAXIMUM LOAD VOLTAGE CANNOT BE OBTAINED Determine that the primary of the circuit transformer is connected to the same supply as the controller and load Typically this problem is caused by the primary being connected across the
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